A-Arm Replacement - Polaris 2008 sportsman 800efi Service Manual

BODY / STEERING / SUSPENSION

A-Arm Replacement

Vehicle Frame
37 ft.lbs. (50 Nm)
1. Elevate and safely support vehicle with weight removed from front wheel(s).
2. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud.
3. Using a soft face hammer, tap nut to loosen A-arm from bolt. Remove nut and A-arm from hub strut assembly.
4. Loosen two bolts on A-arm tube by alternating each about 1/3 of the way until A-arm can be removed.
5. Examine A-arm shaft. Replace if worn. Discard hardware.
6. Insert A-arm shaft into new A-arm.
7. Install CV joint shields.
8. Install new A-arm assembly onto vehicle frame. Torque new bolts to specification.
9. Attach A-arm to hub strut assembly. Tighten ball joint nut to specification. If cotter pin holes are not aligned, tighten nut
slightly to align. Install a new cotter pin with open ends toward rear of machine. Bend both ends in opposite directions around nut
5.20
A-Arm Tube
A-arm Shaft
A-Arm to Frame Bolt Torque: 37 ft. lbs. (50 Nm)
WARNING
The locking features on the existing bolts were
destroyed during removal. DO NOT reuse old
bolts. Serious injury or death could result if
fasteners come loose during operation.
A-Arm to Strut Bolt Torque: 30 ft. lbs. (41 Nm)
WARNING
Upon A-arm installation completion, test vehicle at
low speeds before putting into regular service.
Bolt - 37 ft.lbs. (50 Nm)
Bushing
30 ft.lbs. (41 Nm)
Cotter Pin - (Install New)
= T
= T
™
Apply Loctite 242
to the bolt threads.
Ball Joint Stud
8 ft.lbs. (11 Nm)